Note: This operation will require a spring compressor and new slinger caps.
1. Lubricate the valve stems and insert them into the guide bushings in their original places. When installing new valves, insert them in the places where they were rubbed.
2. Install the thrust washer.
3. Working on the first valve, dip the valve stem seal into fresh engine oil. Usually new caps are supplied with protective sleeves, which must be installed on top of the valve stems to protect the caps during installation from damage from the keyway grooves. If bushings are missing, wrap a small amount of thin tape around the top end of the valve stem. Place the cap carefully on the valve stem and carefully slide it onto the guide bushing. Be careful not to damage the cap when moving over the valve stem. Use a wrench socket or a metal tube to fit the caps tightly onto the guide bushings.
4. Install the valve spring on the support washer, and then install the upper spring plate.
5. Compress the spring and insert two crackers into the groove on the valve stem. Slowly release the spring, then repeat the steps for other valves.
Advice. To keep the cotter pins from falling out when the spring is released, lubricate them with a small amount of grease.
6. After installing all the valves, place the head on a flat, hard surface and hammer the valve stems through the spacer of wood so that all parts are in place.
7. Where provided, install the thermostat housing to the cylinder head.
8. Where required, screw in the spark plugs.
9. Install the pusher cam gear, valve lifters and camshaft as described in Part A of this Chapter.
10. Install the intake and exhaust manifolds as described in Chapter 4.
11. Install the cylinder head as described in Part A of this Chapter.
Six-cylinder petrol engines
12. Follow the steps described in paragraphs 1-8, inclusive.
13. Install the pusher cam gear, valve lifters and camshaft as described in Part B of this Chapter.
14. Install the intake and exhaust manifolds as described in Chapter 4.
15. Install the cylinder head as described in Part B of this Chapter.
Diesel engines
16. Follow the steps described in paragraphs 1-7, inclusive.
17. If required, screw in the glow plugs as described Chapter 5.
18. Install the intake and exhaust manifolds as described in Chapter 4.
19. Install the cylinder head as described in parts of this chapter.